Resilient structural beam



Feb. 27, 1968 H. c. DUPUIS ET AL 3,370,391

RES ILIENT STRUCTURAL BEAM Filed Sept. 7, 1965 INVENTORS HARLAN C. DUPU/S DEANE w ROCKWE ATTORNEY United States Patent 3,370,591 RESILIENT STRUCTURAL BEAM Harlan C. Dupuis, Grinda, and Deane W. Rockwell, Alameda, Calif assignors to Kaiser Gypsum Company, Inc, Oakland, Calif., a corporation of Washington Filed Sept. 7, 1965, Ser. No. 485,167 6 Claims. (Cl. 52-346) ABSTRACT OF THE DISCLOSURE A resilient runner or structural beam useable in wall, and ceiling structures and the like and comprised of a pair of offset spaced planar bearing portions and an intermediate sinuously curved integral web connecting said planar bearing portions together. One of the arcuate sections making up said web having a greater arcuate extent and more generous radius than another arcuate section making up said web. One of the arcuate sections is also directly connected to one planar bearing portion and another arcuate section is directly connected to the other planar bearing portion as well as to the first mentioned aIcuate section.

This invention relates to a resilient structural beam or runner useable particularly in wall, ceiling and lloor structures or various combination thereof which are purp osely designed and constructed to reduce the transmission of sound. More particularly, it is concerned with providing a resilient beam or runner which can be readily spliced to a similar beam or runner without deteriously affecting the beams resiliency and other advantageous characteristics and Without the necessity of supporting such beams in the area were splicing of the same occurs.

In prior building construction practices resilient beams or runners have been used as intermediate anchoring elements for securing wallboards, dry wall units and floor panels in a resilient fashion to studding, joists, etc. whereby the interdisposed resilient beam or runner advantageously acts to attenuate sound transmission through the main wall, floor or ceiling covering members. The configurations of such beams, however, were such that the beams did not lend themselves to being readily spliced together at their ends and they frequently had to be joined together in such a fashion that their ound attenuation characteristics were adversely affected.

Accordingly, it is the primary purpose of the instant invention to provide an improved resilient sound attenuating structural beam or runner wherein the configuration of the beam allows satisfactory and even unsupported splicing 'of one beam with another beam of similar configuration without at the same time adversely affecting the resiliency, sound attenuation and other advantageous characteristics of either of the spliced beams.

These and other purposes and advantages of the instant invention will become more apparent from a review of the following detailed description when taken in conjunction with the appended drawings, wherein:

FIG. 1 is an enlarged fragmentary perspective view of a pair of spliced structural beams embodying the instant invention and illustrates how the beams are joined together at their adjoining longitudinal ends in overlapping relation;

FIG. 1A is a cross-sectional view of the structural beams taken on the line 1A1A of FIG. 1.

FIG. 2 is a sectional View with parts removed generally taken along line 2-2 of FIG. 4 illustrating the crosssection of a beam of the instant invention and further illustrating in dotted lines a modification thereof;

FIG. 2a is a broken sectional view similar to FIG. 2 and illustrates in dotted lines a slightly modified form of the beam of FIG. 2 and an operative resilient position of certain parts thereof of the beam of FIG. 2 relative to their removal position as shown in solid lines in FIG. 2;

FIG. 3 is a sectional view on an enlarged scale generally taken along line 33 of FIG. 2 and rotated 90 clockwise; and

FIG. 4 is a perspective view of a typical wall structure formed of studding, resilient structural beams embodying the instant invention and a portion of a panel member, such as plasterboard or wallboard, secured to the structural beams.

With further reference to the drawings, a preferred form of beam or runner 10 that can be used in carrying out the teachings of the instant invention generally comprises one or more beam sections 12 and 14 that have been roll formed into substantially the same configuration as shown, not only to facilitate splicing or joining together of the beam sections in a unique overlapping fashion at their adjoining longitudinal ends, but also to provide an overall resilient beam 10 of desired length as will be described hereinafter in detail. Although only two beam sections 12 and 14 are shown, it is obvious that any number of sections can be employed depending on the length of final beam desired in a given wall, floor or ceiling structure.

spaced and substantially planar bearing portions 16 and 1-8 which can be disposed in planes generally parallel to each other as shown in solid lines in FIG. 2 or in convergent planes as indicated in dotted and solid lines in FIG. 2. The free marginal edge of the planar portion =18 which is preferably larger than portion 16 and offset is folded back upon itself to form a unique downwardly extending and inwardly directed flange '20 desirably disposed at an angle, preferably an acute angle in the range of 60 to to the underlying surface of the planar portion 18. This flange 2i) contribute to the rigidity and overall strength of the sections 12 or 14, as the case may be, and also functions, as will be more apparent hereinafter, to limit the relative resilient movement between the spaced portions '16 and 18 and to enable splicing of beam sections 12 and 14 at their adjoining longitudinal ends. It is further observed that the more the angle of the flange 20 approximates 85, the easier it i to nest to gether two beams 10 during splicing. The free marginal edge of the other spaced portion '16 can include a foldedover flange 22 that contributes to the rigidity and overall strength of the beam sections 12 and 14 making up the structural beam 10.

Planar spaced portions 16 and 18 are -joined together by an integrally formed intermediate integral web portion 24 of greater length than flange 20 and comprising reversely or sinuously curved arcuate parts or sections 26 and 28. The arcuate part 26 is advantageously formed so as to have a greater arcuate extent and more generous radius than the arcuate extent and radius of arcuate part 28. For example, the radius of section 26 can be on the order of of an inch and the radius of section 28 can be on the order of ,5 of an inch. The curved part 26 along its longitudinal extending edge is connected to one edge of the bearing portion .18. Similarly, the curved part 23 is connected along it longitudinally extending edge to an edge of the other bearing portion 16.

The curved parts 26 and 28 of the intermediate portion 24 act as a spring connector between bearing portions 16 and 18 and advantageously contribute to the overall resiliency of the portions 16 and 18 relative to each other in response to forces or force components exerted in a direction normal to the planar surfaces of the spaced portions 16 and 18. To further contribute to the resiliency of the spaced portions 16 and 18, the intermediate portion 24 can advantageously have a series of perforations 30 pro- Each of the beam sections *12 and 14 is made up of vided therein with these perforations 30 being disposed along a common longitudinal axis. As best shown in FIG. 3, these perforations 30 can have the shape of elongated openings. Perforations 30 are preferably located within the curved part 26 and substantially immediately above the point of interconnection of the integrally formed curved components 26 and 28. Further, the perforations 30 can be located Within the curved part 28 and substantially immediately above the point of interconnection of the bearing portion 16 and the curved component 28 as shown by dotted lines in FIG. 2a. The size and spacing between successive perforations 30 should always be such as to enhance the resiliency between bearing portions 16 and 18 without sacrificing the desired rigidity and overall strength of a beam section 12 or 14. Bearing portion '16 is further provided with a series of spaced perforations 34 for anchoring the beam section to an underlying support means or grid such as the spaced wall stud members 36 shown in FIG. 4 in a manner conventional in the art.

During formation of a beam section 12 or 14, the upper surface of the bearing portions 18 can be provided with a pattern of intersecting score lines generally indicated at 38 or any other suitable deformation. Although only two such rows of exemplary deformations 38 are shown in the beam sections 12 and 14 of FIG. 1, which are arranged number can be used and the rows of the deformations relatively close together, it is to be understood that any making up the pattern would ordinarily cover substantially the entire exposed upper surface of bearing portion 18 in a beam section 12 or 14.

The point of intersection of each of the score lines 38 serves as a guiding and centering means for a fastener element 40 during penetration of bearing portion 18 by element 40 used to anchor a panel thereto. To assist penetration by the element 40, the deformations 38 can actually, if desired, be deformed inwardly, by a suitable roll forming tool, so as to define a funnel-like depression. The fastener element 40 usually is a self-tapping screw that can be first driven through a surface covering member or panel 42 by a suitable tool, such as a screwdriver, not shown. In the event that the first attempt to drive the fastener 40 through the surface member 42 does not result in alignment of the fastener 40 with a point of intersection of score lines 38 on the underlying beam 10, the fastener itself then usually inclines automatically until the point of intersection of one of the intersecting score lines 38 of the closely arranged deformations is in alignment with the forward end of the driven fastener element 40. Once the fastener element 40 is in alignment with such a point of intersection, further driving of the fastener element 46 by the tool effects relatively easy penetration of bearing por:

tion 18. Such penetration punctures and deforms parts of i the bearing portion 18 into tight engagement with the forward end of the driven fastener element 40 so as to positively hold the fastener element and, in turn, the surface covering member 42 to the underlying beam so as to positively secure a surface member 42 thereto.

By virtue of the unique shape of the various parts 26 and 28 of intermediate portion 24 in combination with the angular disposition of the unique inwardly directed flange 20, beam sections 12 and 14 can advantageously be spliced together at their adjoining longitudinal ends in overlapping relation. With reference to FIG. 1, the adjoining longitudinal end of a beam section 12 is preferably attached to the adjoining longitudinal end of a beam section 14 in such a fashion that the oppositely facing surfaces of the flanges 20 and the intermediate portion 24 at the said adjoining ends can be disposed in positive mating surface-to-surface contact with each other. The generous radius of curved section 26 permits sufficient flexure and an opening of one end of a beam section, such as section 14, sufliciently to snugly receive the opposing end of a similar beam section 12 without seriously or severely distorting the original shape of section 26 of the first beam section 14 at the point of splice between sections 12 and 14. This is rendered even easier where intermediate portion 24 is perforated as noted above. Flange 20 of the lapping beam, such as section 14, can also be displaced sufficiently to receive the underlying flange 20 of beam section 12.

Such endto-end jointure of the beam sections 12 and 14 advantageously results in a rigidly spliced beam 10 of a predetermined length. Because of the tight joint or splice brought about by the interlock between the sections 24 and 20 of the beam sections 12 and 14, the overall spliced beam 10 need not be supported in the immediate area of the splice. Depending upon the particular building code requirements involved, any number of beams 10 or beam sections can be atfixed to the studs 36 or joists. After aflixation of the beams 10, the wallboard 42 can be secured by the screws 40 in the aforedes-cribed manner to the bearing portion 18 of the underlying beam section 12 or 14 as the case may be. Whenever a load, such as sound vibration, is applied against the fastened wallboard 42 the spaced portions 16 and 13 will have relative displacement towards each other and result in resilient collapsing of the intermediate portion 24 as indicated by dotted lines in FIG. 2. The amount of collapse is controlled by engagement of flange 25) with the understructure such as a stud 36. In addition to performing this function, flange 2i) acts as a stop during driving of a panel fastener into bearing portion 18 whereby the fastener 40 is prevented from engaging the underlying structure such as studding and from bringing about a permanent collapse of web portion 24 and a locking of the bearing portion 18 to the studding by means of a fastener 48.

As noted above, the splice between adjacent beam sections need not be supported in the area of the splice. Further, such snug splicing for all practical purposes eliminates any rattling sounds of the affixed beam '10 when loads are imposed upon the surface member 42 and studs 36, and the like. If desired, the overlapped extent of the flange 22 on the beam section 12 between the joined beam sections 12 and 14 can be cut away prior to their jointure as aforedescribed to facilitate such jointure.

Finally, it is to be understood that any number of beam sections of given lengths can be spliced together at their adjoining longitudinal ends so as to fabricate a resilient structural beam of any required length.

An advantageous embodiment of the invention has been shown and described. It is obvious to those skilled in the art that various changes and modifications may be made therein without departing from the spirit and scope thereof as set forth in the appended claims.

What is claimed is:

1. A resilient runner made of readily flexible. material and comprising a pair of offset spaced planar bearing portions and an intermediate sinuously curved integral 'web connecting said planar bearing portions together, one' of the arcuate sections making up said web having a'greater arcuate extent and more generous radius than another arcuate section making up said web, one of the arcuate sections also being directly connected to one planar bearing portion and another arcuate section being directly connected to the other planar bearing portion as well as to the first mentioned arcuate section and an inwardly directed stop flange formed integrally with one of the planar bearing portions and of a shorter length than said Web, said stop flange being arranged at an acute angle of at least 60 relative to said last mentioned bearing portion.

2. A resilient runner as set forth in claim 1, wherein said stop flange is arranged at an acute angle of between 60 to relative to said last mentioned bearing portion.

3. A resilient runner as set forth in claim 1, wherein one of said bearing portions is provided with a series of fastener penetrating deformations.

4. A resilient runner as set forth in claim 1, wherein one of said arcuate sections is perforated.

5. An elongated composite resilient runner comprised of a pair of similarly configured beams spliced together in overlapping relationship, each of said beams being made of a readily flexible material and having a pair of olfset spaced planar bearing portions and an intermediate sinuously curved integral web connecting said planar bearing portions together, one of the arcuate sections making up said web having a greater arcuate extent and more generous radius than another arcuate section making up said web, one of the arcuate sections also being directly connected to one planar bearing portion and another arcuate section being directly connected to the other planar hearing portion as well as to the first mentioned arcuate section and one of the planar portions in one of said beams being provided with a stop flange formed integrally therewith and of a smaller length than the web of the beam with which it is associated, said stop flange also being arranged at an acute angle of at least 60 relative to said last mentioned bearing portion.

6. A composite resilient runner as set forth in claim 5, wherein said stop flange is arranged at an acute angle of between 60 and 85 relative to the planar portion with which it is associated.

References Cited UNITED STATES PATENTS 104,865 6/1870 May 52342 945,682 1/1910 Berg 52588 333,603 1/1886 Cortright 52-726 X 2,073,781 3/ 1937 Calafati 52-342 3,090,164 5/1963 Nelsson 52346 3,177,620 4/1965 Brown et al 52-488 3,188,772 6/1965 Tennison 52726 X 3,243,930 4/ 1966 Slowinski 52--363 X BOBBY R. GAY, Primary Examiner.

A. CALVERT, Assistant Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3, 370,391 February 27, 1968 Harlan C. Dupuis et al.

It is certified that error appears in the above identified patent and that said Letters Patent are hereby corrected as shown below:

Column 1, line 28, "combination" should read combinations line 35, "were" should read where Column 2, line 3, "removal" should read normal Column 3, line 27, cancel 'relatively close together, it is to be understood that any number can be used and the rows of the deformations" and insert same after "arranged" in line 25, same column 3.

Signed and sealed this 17th day of March 1970.

(SEAL) Attest:

WILLIAM E. SCHUYLER, JR.

Commissioner of Patents Edward M. Fletcher, Jr. Attesting Officer 

